JCB 426, 436, 446 Wheeled Loading Shovel Service Manual – 9803/4160-15

This workshop repair service manual PDF download for the 426, 436, 446 JCB Wheeled Loading Shovel has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JCB Wheeled Loading Shovel 426 – from machine serial number 531001
JCB Wheeled Loading Shovel 436 – from machine serial number 533001
JCB Wheeled Loading Shovel 446 – from machine serial number 540000 to 540011

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Routine Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H – Hydraulic Steering
Section K – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/4160-15
Total Pages : 1095

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-4160

Section 1 – General Information
General Information
Introduction
About this Publication
Identifying your Machine
Identification Plates
Identification Plate
Explanation of Vehicle Identification Number (VIN)
Unit Identification
Typical Engine Identification Number
Torque Settings
Zinc Plated Fasteners (golden finish)
UNF Grade `S’ Bolts
Metric Grade 8.8 Bolts
Rivet Nut Bolts/Screws
Service Tools
Numerical List Section B – Body and Framework
Tool Detail Reference Section B – Body and Framework
Numerical List Section C – Electrics
Tool Detail Reference Section C – Electrics
Numerical List Section E – Hydraulics
Tool Detail Reference Section E- Hydraulics
Numerical List Section F – Transmission
Tool Detail Reference Section F – Transmission
Numerical List Section K – Engine
Tool Detail Reference Section K – Engine
Service Consumables
Sealing and Retaining Compounds

Section 2 – Care and Safety
Care and Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Decals

Section 3 – Routine Maintenance

Section A – Attachments
Attachments
Optional Attachments
Quick Release Couplings
Connecting and Disconnecting

Section B – Body and Framework
Body and Framework
Technical Data
Air Conditioning Option
Basic Operation
Air Conditioning
R134a Refrigerant
System Operation
System Control
Safety Procedures
Fault Finding
Air Conditioning
Visual Inspection
System Diagnosis
Service Procedures
Rivet Nuts
Fitting Procedure
Air Conditioning
Checking Refrigerant Charge Level
Leak Testing
Tightening Leaking Hoses
Refrigerant Charging and Discharging
Pressure Switch Assembly (Two Switch System)
Binary Pressure Switch Testing (Single Switch System)
Condenser
Air Conditioning
Early Type
The Air Conditioning Unit
The Blower Unit
Thermostat
Evaporator
Pressure Switches
Later Type
The Air Conditioning Unit
The Blower Motor
Thermostat
Evaporator
Air Conditioning – 426 from M532100, 436 from M533700
426 from M1231500, 436 from M1305000
The Air Conditioning Unit
Filters
Blower Motor
Thermostat
Evaporator
Expansion Valve
Heater Radiator
Binary Pressure Switch
Cab
Glazing
Direct Glazing
ROP/FOPS Structure
426 prior to M1231500, 436 prior to M1305000
426 from M1231500, 436 from M1305000
Bodywork
Removal and Replacement of the Rear Bodywork
Removal
Replacement
Centre Pivot
Removal and Replacement
Removal
Replacement
Cooling Pack
426 from Serial No. 532500
Removal and Replacement (426 from Serial No. 532500)
Dismantling and Assembly
436 from Serial No. 534200
Removal and Replacement
Dismantling and Assembly
426 from M1231500, 436 from M1305000
Introduction
Removal

Section C – Electrics
Electrics
Technical Data
General Electrical Data
Light Bulbs
Fuses and Relays
426 to M531064, 436 to M533069
426 from M531065, 436 from M533070
426 from M531300, 436 from M533300
446 from 540000
426 from M532100, 436 from M533692
426 from M532429, 436 from 534089
426 from M532847, 436 from M534468
426 from M1231500, 436 from M1305000
426 from M1295000, 436 from M1410000
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
First Aid – Electrolyte
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starter Motor
Starting Circuit Test
Electronic Monitoring System (EMS)
HC11 Display Panel
C164 Display Panel
24 – 12 Volt Power Distribution Board
Fault Finding
Introduction to Fault – Finding Techniques
Harness Routing
Example of Wire Tracing
Component Testing
Schematic Circuits
426 to 531064, 436 to 533069
426 from 531065, 436 from 533070
426 from 531300, 436 from 533300
446 from 540000
426/436 from March ‘98
446 from March ‘98
426 from 532100, 436 from 533692
426 from 532847, 436 from 534468
Auxiliary Circuits (426 from 532847, 436 from 534468)
436 Machines – Italian Military Only
426 from M1231500, 436 from M1305000
Instrumentation
ZF Computer and Gearbox Controller
Front Wipe, Rear Wipe, Heater/AC and Heated Rear Screen
Front and Rear Worklights and Beacon
Roadlights
Radio, Cigar Lighter, CCTV and Tow Hitch
ESOS, Heated Mirrors, Heated and Suspension Seat, Reverse Fan and Emergency Steer
12Volt Trailer Electrics and Loader Functions
Loader Auxiliaries (Proportional)
Earthing – Cab and Cab Roof
Earthing – Front and Rear Chassis
426 from M1295000, 436 from M1410000
Primary Fuses, Ignition Switch and Ignition Relays
Instrumentation
ZF Computer and Gearbox Controller
Tier 3 Engine ECU
Front Wipe, Rear Wipe, Heater/AC
Front and Rear Worklights and Beacon
Roadlights
Radio, Cigar Lighter, CCTV and Tow Hitch
ESOS, Heated Mirrors, Heated and Suspension Seat, Reverse Fan and Emergency Steer
12Volt Trailer Electrics and Loader Functions
Loader Auxiliaries (Proportional)
Earthing
Harness and Wire Number Identification
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Connector Location and Identification
426 from M531064, 436 from M533069
426 from M531300, 436 from 533300, 426 from 540000
Harness Drawings
Front Chassis Harness A & B – 426 from M531064, 436 from M 533069
Rear Cab Harness A & B – 426 from M531064, 436 from M 533069
Rear Chassis Harness A – 426 from M531064, 436 from M 533069
Rear Chassis Harness B – 426 from M531064, 436 from M 533069
Side Console Harness A – 426 from M531064, 436 from M 533069
Side Console Harness B – 426 from M531064, 436 from M 533069
Cab Roof Harness A & B – 426 from M531064, 436 from M533069
Front Chassis (HT) Harness – 426 from M531300, 436 from M533300, 446 form M540000
Front Chassis (ZX) Harness – 426 from M531300, 436 from M533300, 446 from M540000
Rear Chassis Harness – 426 from M531300, 436 from M533300
Rear Chassis Harness – 426 from M531300, 436 from M533300
Rear Chassis Harness – 446 from M540000
Rear Chassis Harness – 446 from M540000
Rear Chassis Harness – 426 from M531516, 436 from M533478
Rear Chassis Harness – 426 from M531516, 436 from M533478
Side Console Harness – 426 from M531516, 436 from M533478
Side Console Harness – 426 from M531516, 436 from M533478
Side Console Harness – 426 from M531516, 436 from M533478
Rear Cab Harness – 426 from M531516, 436 from M533478
Cab Roof Harness – 426 from M531516, 436 from M533478
Controller Harness – 426 from M531516, 436 from M533478
Rear Grille Harness – 426 from M531516, 436 from M533478
Under Bonnet Harness – 426 from M531516, 436 from M533478
Front Chassis Harness HT – 426 from M532100, 436 from M533692
Front Chassis Harness ZX – 426 from M532100, 436 from M533692
Rear Chassis Harness – 426 from M532100, 436 from M533692
Side Console Harness – 426 from M532100, 436 from M533692
Side Console Harness – 426 from M532100, 436 from M533692
Side Console Harness – 426 from M532100, 436 from M533692
Side Console Harness – Smoothshift
Side Console Harness – Smoothshift
Side Console Harness – Smoothshift
Side Console Harness – Smoothshift
Rear Cab Harness – 426 from M532100, 436 from M533692
Cab Roof Harness – 426 from M532100, 436 from M533692
Engine Harness – 426 from M532100, 436 from M533692
Transmission Harness – 426 from M532100, 436 from M533692
Canopy Harness – 426 from M532100, 436 from M533692
Canopy Harness – 426 from M532100, 436 from M533692
Canopy Harness – 426 from M532100, 436 from M533692
Canopy Fuse Box Harness – 426 from M532100, 436 from M533692
Canopy Fuse Box Harness – 426 from M532100, 436 from M533692
Canopy Fuse Box Harness – 426 from M532100, 436 from M533692
Proportional Solenoid Harness – 426 from M532100, 436 from M533692
Proportional Change Over Harness – 426 from M532100, 436 from M533692
Bang – Bang Solenoid Harness – 426 from M532100, 436 from M533692
Drawings and Interconnection
Harnesses 426 from M1231500, 436 from M1305000
Harnesses 426 from M1295000, 436 from M1410000
Drawings
Electronic Monitoring System
System Identification
General
HC11 EMS
Description
Connecting up the Laptop
Before Starting Service
On completion of Service
HC11 EMS – Software
Installation
Installation from Techweb
Transfer New Program
Serial Number
Log Data
Fault Limit Settings
Connection of Interrogation Lead
C164 EMS
General
EMS Tools
Flash Loader Program
Set-up Program
Diagnostic Program
Service History Program
Data Logger Program
Connecting the Interrogation Lead
Alternator
S11524-7 Alternator
Removal and Replacement
Dismantling and Assembling
A5524 Alternator
Dismantling
Inspection, Testing and Repair
Rotor
Bearings
Slip ring end bearing – Removal and Replacement
Drive end bearing – Removal and Replacement
Slip ring end housing – Removing Rectifier
Refitting rectifier
To remove and refit D+ and F- leads
Brush holder assembly
Stator and housing
Re-assembly
Testing
Rectifier testing
Testing
Regulator Check
Starter Motor
426 and 436 Machines
Removal and Replacement
Dismantling
Servicing and Renewal
Assembly
446 Machines
Removal and Replacement
Dismantling
Cleaning
Assembly
Setting the Drive Pinion Clearance (446)
No Load Test (446)

Section E – Hydraulics
Hydraulics
Technical Data
426 Machines up to Serial number 532099
Pump
Loader Valve
436, 446 Machines
Primary Pump
Secondary Pump
Loader Valve
Smoothshift Machines: 426 from S/N: 532100, 436 from S/N: 533692
Pump
Loader Valve
Auxiliary Relief Valves (A.R.V.)
426 from S/N: 532500, 436 from S/N: 534200
Pump
Loader Valve
Auxiliary Relief Valves (A.R.V.)
426 from S/N: 532847, 436 from S/N: 534469
Pump
Loader Valve
Auxiliary Relief Valves (A.R.V.)
Accumulators
426 from M1231500, 436 from M1305000
Pump
Loader Valve
Auxiliary Relief Valve (ARV) Settings
Accumulators
Basic Operation
General Description
426
436
Valve Block Tie-Rods
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Circuit Diagrams
426 to M531203, 436 to M533195
426 with 4-Ram Loader
426 with Z-Bar Loader
436 with 4-Ram Loader
436 with Z-Bar Loader
426 from M531204, 436 from M533196
426 with 4 Ram Loader
426 with Z-Bar Loader
436 with 4-Ram Loader
436 with Z-Bar Loader
Smoothshift Machines (426 from M532100, 436 from M533692)
426, 436 with 4 Bar Loader
426, 436 with Z-Bar Loader
436 from M534200 (Tier II)
436 HT
436 ZX
426 from M532847
426 HT
426 ZX
436 from M534469
436 HT
436 ZX
426 from M1231500, 436 from M1305000
Schematic Diagrams
Circuit Descriptions
Pump Operation
Pump Pressure/Flow Regulator Valves
Start Up
Hydraulic Service Operated
Minimum Flow/Maximum Pressure
Start Up Valve
Loader Valve
Loader Valve – Arms Raise/Lower
Loader Valve – Shovel Float
Loader Valve – Shovel Tip (4-Ram Loader)
Loader Valve – Shovel Crowd (4-Ram Loader)
Loader Valve – Shovel Tip (Z-bar Loader)
Loader Valve – Shovel Crowd (Z-bar Loader)
Compensator Spool – Operation 1
Compensator Spool – Operation 2
Auxiliary Services
Servo Pressure Regulating Valve
Neutral Standby Pressure
Service Operating
Automatic Carry Control System (ACCS)
Introduction
Hydraulic Circuit
Operation
Maintenance Safety
ACCS 426 from M1231500, 436 from M1305000
General
Circuit Descriptions
Maintenance Safety
Electronic Emergency Steering
General
Fault Finding
Hydraulic Fault Finding
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Venting the Hydraulic Pressure
426 from M1231500, 436 from M1305000
Automatic Carry Control System Venting
Connecting and Disconnecting Hydraulic Hoses
Connecting the Hoses
Disconnecting the Hoses
`Positional Type’ Hydraulic Adaptors
Fitting Procedure
Flow and Pressure Tests
Main Pump – 426 Machines
Main Pump – 436, 446 Machines
Pressure Testing the Loader Valve A.R.V.’s Using a Hand Pump
Tandem Pumps
Servo Pressure – Tandem Pumps
Steering Relief Valve
Two-Stage Shovel Ram (Head Side)
Idle Control Setting
426, 436 Machines
Hydraulic Cooling Fan Setting
436 Machines to M1305000
Reversing Fan Software
Programming the Reversing Fan Frequency and Duration
426 Machines from M1231500, 436 Machines from M1235000
Emergency Steering (Electronic)
Checking/Adjusting the System Pressure
Automatic Carry Control System (ACCS)
Accumulators
Dismantling, Inspection and Assembly
Pumps
426 Machines Removal and Replacement
When Removing
When Replacing
436 Machines Removal and Replacement (Primary)
When Removing
When Replacing
436 Machines Removal and Replacement (Secondary)
When Removing
When Replacing
Tandem Pumps – 426, 436
General
Removal and Replacement
Replacing the Pressure/Flow Regulator
Renewing Drive Shaft Seal
Dismantling, Inspecting and Assembly
Dismantling
Inspecting
Assembly
Emergency Steering
426 from S/N 532847, 436 from S/N 534469
Removal and Replacement
Cooling Fan Motor
436 from M534200
Removal and Replacement
Replacement
Dismantling, Inspection and Assembly
426 from 1231500, 436 from 1305000
Removal
Replacement
Uni-Directional Motor
Bi-Directional Motor
Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Typical Ram
Dismantle and Assembly
JCB Ram Sealing Procedure
Piston Head Retention
Z Rams
Z Ram
436ZX Ram
Dismantling the piston rod from cylinder tube
Dismantling the piston rod
Removing the piston seals
Removing the cylinder head seals
Assembling the piston seals
Assembling the cylinder head seals
Assembly of piston rod with cushion ring on the piston rod side
Assembly of piston rod with cushion ring on the piston rod and cylinder bottom side
Assembly of piston rod in cylinder tube

Section F – Transmission
Transmission
Technical Data
426 and 436
Drive Axle – Front & Rear
Transmission
Powershift Transmission
WG 150, WG 200
Control Valve
Charge Pump
Coaxial Power Take-off
Lateral Power Take-off
Layshaft
Final Drive
Multi-Disc Clutches
Clutch K4/K3
Clutch KR/K2
Clutch KV/K1
Emergency Steering Pump
WG 160, WG 190
Main Components
Oil Circulation Schematic
Power Flow – Forward Speeds
Power Flow – Reverse Speeds
Test points and connections
Electro-Hydraulic Shift Control
Dismantling and Assembly
Assembly
Hydraulic Control Unit –
Fault Finding
Functional Testing
Semi – automatic
Test Procedure (Automatic)
Transmission Fault Finding
Fault Codes (4WG-160/190/210)
Service Procedures
Electronic Monitoring System (EMS) Display Panel
Removal and Replacement
Replacement
Replacement of Loader Arm Control Transmission Dump and Kickdown Switches
Replacement of Wiring to Kick down and Transmission Dump Switches
Removal and Replacement of Control Lever
Propshafts
Basic Operation
Removing and Replacing
Axles
Front Axle
Removal
Replacement
Rear Axle
Removal
Replacement
Rear Axle – Heavy Duty
Removal
Replacement
Hub and Driveshaft
Dismantling
Assembly
Drive Head
Dismantling
Overhauling Pinion Bearing Support
Pinion Depth
Assembly
Crown Wheel and Pinion
Adjustment
Correct Pattern
Incorrect Pattern – High Contact
Incorrect Pattern – Low Contact
Limited Slip Differential Unit
Dismantling
Assembly

Section G – Brakes
Brakes
Brake Circuits
Service Procedures
Brake Valves
Parking Brake
Technical Data
446 (from S/N: 540000 to 540011)
426/436
Brake Circuits
426 To Serial Number 532099, 436 to Serial Number 533691, 446 from Serial No. 540000 to 540011
426 from S/N: 532100, 436 from S/N: 533692
436 from S/N: 534200 (Tier II)
Service Procedures
Service Brakes
System Testing
436 from Serial No. 534200 – (Tier II, with Hydraulic Engine Cooling Fan
Brake Pressure Setting
Bleeding the System
System Accumulators
Charging the Accumulators
Parking Brake (Type 1)
Adjusting the Parking Brake
Adjusting the Brake Pads
Adjusting the Cable Slack
Renewing the Brake Pads
Parking Brake (Type 2)
Adjusting the Parking Brake
Adjusting the Cable Slack
Renewing the Brake Pads
Park Brake Testing
Pre Smoothshift Machines
Smoothshift Machines
Brake Valves
Foot Valve
Removal and Replacement
Dismantling and Assembly
Parking Brake
Type 1
Dismantling and Assembly
Type 2
Dismantling
Assembly

Section H – Hydraulic Steering
Hydraulic Steering
Technical Data
General data
Pump
Circuit Descriptions
Steering Operations
General Description
Steering Valve – Operation
Hydraulic Steering Unit
Dismantling and Assembly
Dismantling
Inspecting
Assembling
Emergency Steering Pump
Dismantling and Assembly
When Dismantling
When Assembling

Section K – Engine
Engine
Technical Data
426 and 436
446
426B and 436B
426 from Serial No. 532500
436 from Serial No. 534200
426e from Serial No. 1295000
436e from Serial No. 1410000

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